counter shaft washer swap

[mack]

Anyone but me find that second gear is bound up after doing the washer swap?

[Rasputin]

Have only done it twice on my bikes and a third time on another members bike, so far, but no complaints on that issue.

[Radioguylogs]

Mack:

Don't have experience with the washer swap yet, but wondering what "bound up" means. Does it mean it is stuck in second gear?

[mack]

Bound

It just doesn't spin on the shaft freely like it should. Like the first or third gear, you can turn it but not spin it like it should! Maybe I distorted the clip, I had heck of a time working it out.

[bikerphil]

Yes, the clip can get distorted and cause that gear to bind, hammer it flat before installing on the countershaft. Make sure 2nd gear spins freely, it may affect shifting otherwise.

[mack]

Tool

there must be a tool to remove those flat clips without distorting them. Got a link?

[cajun31]

I have not

done this as of yet either but a thought came to mind. May be way off base but curiosity makes me ask. If the washer is distorted and binding ... is that because of how tightly it sits on the shaft? If that is true couldn't the inside diameter of the washer be made larger to give it more play so that it does not sit so tightly? I was thinking that the whole purpose of the washer is to limit lateral movement of the gear while engaged so having a little more play on the inside circumference shouldn't cause any problems other then a bit more vibration/ i.e. chatter possibly but I think that would be at a minimum. JAT and how far out there am I?

[cajun31]

OK reread the thread.... what does the clip you are talking about look like? I was assuming clip and washer were one in the same. I am curious because this sounds like a good proactive mod to perform before the 2nd gear problems arise. Pictures would be great if you have them.

[mack]

Pictures

Give me few minutes and I'll take some and post them. The washer swap has been around for a long time, first done by Bob Jones, so I know it should be easy and work like a charm. He did recommend doing this as preventive maintnance. It just allows 2cd and 5th gears a little more contact(width of washer) to prevent skipping. The issue is really, how to get the darn clip in and out of the recess without distorting it. There has to be a good tool for this something like a set of pliers or a piston ring tool.

[ViperRon]

Tool

Had a tool like this was the best at E clips removal and insertion http://www.tecratools.com/product950.html

[bikerphil]

It seems to me that when removing the clip is when it will distort. After straightening it, it can be carefully worked down into position without it bending. I have used a standard snap ring pliers to spread it during installation.

[mack]

Washer Swap

Here you go Cajun.

[mack]

oops

[BA80]

The gear seems tight because there's a bevel cut into the gear that matches the angle that's machined into the shaft itself when the gear is in it's stock position. The washer doesn't so it feels a bit tight. It isn't an issue if you assemble it like that because after the first couple of miles running it seats in.

I've taken the shaft and positioned it with the gear in place protected from being damaged and seated the washer on the shaft with a few good licks of a hammer. That helps some if your worried about it but as I stated, it really isn't an issue.

[mack]

Stupid

Now just feel stupid. After taking the main shaft apart to remove the rust, look what I found. The perfect solution to removing and installing those clips. The one on the left is from the countershaft, right is between the fourth and 2/3 pinion. Simple but elegant.

Why they didn't do that for the countershaft is anyones guess!